Electromagnetic induction apparatus and method of treatment of molten materials

ABSTRACT

As shown in FIG.  3,  flow inducement or stirring apparatus  500  includes electromagnetic induction apparatus in the form of a generally rectangular box  501  connected to an inclined end wall  502  of a cradle or port  503  of the apparatus  500,  being generally of right-angled isosceles triangle cross-section. The inclined wall  502  is angled at 45° to the vertical wall  504  and horizontal wall  505  of the cradle or support  503.  The manner in which the cradle or port  503  can be connected into the vertical end wall  600  of the furnace  601  should be evident from FIG.  3  of the drawings. The port or cradle  503  can be fixed into the wall  600  of the furnace  601  by creating an aperture  602  of an appropriate size and by utilising usual refractory techniques to fix the port in the aperture The electromagnetic induction apparatus  501  is connected to said end wall  502  by any appropriate means and, in use, acts to create circulation of molten metal in the furnace in a vertical plane.

[0001] This invention relates to improvements in or relating to the treatment of molten materials and is more particularly concerned with improved melting/stirring and/or improved movement or transfer of molten metal materials.

[0002] The recycling of scrap metal is increasing, and therefore considerable efforts are being made to improve the efficiency of recycling processes, part of which includes the melting of scrap metal.

[0003] It is known to provide furnaces for the melting and refining of metal materials such as aluminium or other materials. Often such furnaces are utilised to recycle scrap metal. Various proposals have been made to improve the melting and refining process, for example, by stirring the molten metal (and alloy additives where provided) and stirring a mix of molten metal and additional solid-state metal materials introduced into the melt in the furnace. Stirring the molten metal helps the efficiency of the melting process distributing the heat throughout the melt and also helps in melting solid-state scrap material and/or additives, introduced into the melt, more quickly.

[0004] In this connection, it is known to provide a stirring apparatus in the form of an electromagnetic induction unit (in the form of a linear motor) that can be positioned underneath the furnace in a horizontal plane adjacent a bottom wall of the furnace underneath the melt in the use. The magnetic field created by the induction motor acts through a relatively thick plate on the bottom of the furnace and effectively stirs the molten material slowly in a horizontal plane in an attempt to disperse the heat evenly throughout the melt It is also known to employ mechanical stirrers in such furnaces to create a similar stirring action. However, it is believed that such a treatment of molten metal tends to have disadvantages at least in certain applications. For example, when additional scrap metal material or alloy additives such as silicon are introduced into the furnace on top of the melt, the stirring action provided by the electromagnetic induction motor does not contribute greatly to mixing the new scrap metal material/additives evenly throughout the melt. Often the scrap metal material/additive will be quite light (particularly a silicon additive) and will simply float on the surface of the melt as it is stirred around in a horizontal plane rather than, for example, being dragged downwardly into the molten metal where it can be melted much more quickly and effectively. Once again, scrap metal in the form of aluminium drink cans will simply float on the top of the melt and become oxidised rather than being submerged within the bath to be melted down and recycled in an efficient manner.

[0005] Additionally, such induction motor stirring apparatus tends to be slow, for example, operating at 1 Hz. The design constraints for such motors require quite a deep magnetic field to be propagated throughout the full height of the molten material in the furnace so that the horizontal circulatory stirring action takes place throughout the whole of the molten material rather than, for example, in the lower layer of material. Thus, in order to achieve such a depth of magnetic field, a high speed of stirring has to be sacrificed. A much lower speed of stirring is achievable than would otherwise be the case if the material could be stirred using a reduced depth of magnetic field.

[0006] Where mechanical stirrers are provided, these tend to burn out quite quickly and need to be replaced and once again do not appear to have been arranged to act in a manner conducive to submerging scrap metals/additives introduced on top of the melt.

[0007] Once again, it is believed that there tend to be problems in the extraction of the molten metal material once it has undergone treatment in the furnace. The usual manner of extracting the molten metal materials tends to be somewhat dangerous for the operator. A plug may be provided at the bottom of the furnace that can be removed to allow the molten metal materials to flow there through and thus be extracted from the furnace, or, in other arrangements, the furnace has to be tilted in order to pour the molten contents from the furnace. In either case, it is believed that the level of involvement for the operator carries a risk of being harmed by the molten metal materials in a manner which need not necessarily be the case if the method of extraction of molten materials from the furnace were improved.

[0008] It is an object of the present invention to at least alleviate one or more of the aforementioned, or other, disadvantages associated with the treatment of molten materials and/or to provide an improved stirring apparatus, system, stirring arrangement, movement or transfer apparatus, furnace or method.

[0009] According to a first aspect of the present invention there is provided flow inducement or stirring apparatus adapted for inducing downward and/or upward flow of molten metal material and/or circulation of molten metal material in a vertical plane, for example in a furnace.

[0010] Further according to the present invention there is provided a furnace or chamber for treating molten metal materials in combination with at least one flow inducement or stirring apparatus as claimed in the immediately preceding paragraph.

[0011] Further according to the present invention there is provided a furnace or chamber for treating molten metal materials and at least one flow inducement or stirring apparatus arranged, in use, to induce downward and/or upward flow of molten metal material and/or circulation of molten metal material in a vertical plane.

[0012] The flow inducement or stirring apparatus may also be arranged, in use, to create a horizontal flow of molten metal material and/or circulation of molten metal in a horizontal plane e.g. between two or more chambers of a furnace such as a sidewell furnace.

[0013] Usually, the flow inducement or stirring apparatus will comprise or include electromagnetic induction apparatus.

[0014] Usually, the electromagnetic induction apparatus will be arranged, in use, at an angle inclined to the horizontal (typically 40° to 70°) in order to create an upward and/or downward driving force on the molten metal. The electromagnetic induction apparatus may be positioned on an inclined wall of a chamber of furnace, in use, containing molten metal. Where no such inclined wall is available, the induction apparatus may be positioned at angle on a vertical chamber/furnace wall by means of an attachment cradle or port of the flow inducement or stirring apparatus.

[0015] The cradle or port preferably includes an aperture which, in use, leads to molten metal material (e.g. in a furnace) and allows e.g. alloy additives such as silicon to be introduced into the molten metal material and allows samples of the metal to be taken as well as degassing.

[0016] In one embodiment of the invention, the flow inducement or stirring apparatus is arranged to provide a circulating flow in the melt, said circulation being in a vertical plane to enable solid scrap materials/ light additives introduced on top of the melt to be dragged downwardly and submerged under the influence of the molten metal flow created by the flow inducement or stirring apparatus. This creates a more efficient heat dispersal which reduces melt and process times, and also reduces exposure of the scrap metal to an oxidising atmosphere, thereby minimising metal loss by oxidation.

[0017] Preferably, the power or speed of the flow inducement or stirring apparatus will be variable to suit different tasks to be undertaken by the flow inducement/stirring apparatus. For example, if the flow inducement/stirring apparatus is utilised to drive the flow of molten metal in a downward direction e.g. to create a circulation in a vertical plane the speed may be set to a higher level than a scenario where the flow inducement/stirring apparatus is utilised to extract metal from a chamber or furnace. If the speed were to be set too high, on extraction of the metal from the chamber or furnace the material could spurt out dangerously.

[0018] Preferably, the speed of the flow inducement or stirring apparatus may be set to various values up to 50 Kz (+/−10 Hz).

[0019] Preferably, the flow inducement/stirring apparatus is bi-directional to induce flow of molten metal selectively in two opposed directions according to the choice of the operator.

[0020] In one embodiment, where the flow inducement/stirring apparatus is bi-directional and utilised in one direction to create circulation in a vertical plane in order to submerge and mix light scrap materials/additives into the melt, said flow inducement/stirring means may be utilised in its other directional mode to reverse the flow circulation and thus extract molten materials from a chamber or furnace.

[0021] Further according to the present invention there is provided a method of treating molten metal material or recycling scrap metal, said method comprising inducing an upward and/or downward flow of molten metal and/or circulation of molten metal in a vertical plane, preferably by electromagnetic induction apparatus.

[0022] Further according to the present invention there is provided use of electromagnetic induction means for inducing downward/upward flow of molten metal material in a vertical plane, for example in a furnace.

[0023] Further according to the present invention, in a furnace or chamber containing molten metal in use, connecting electromagnetic induction means at an inclined angle to the horizontal to induce a flow of molten metal downwardly and/or upwardly and/or a circulation in a vertical plane.

[0024] Further according to the present invention there is provided electromagnetic induction means adapted or arranged to induce a fast flow in molten metal >1 Hz e.g. 50 HZ (+/−15 Hz).

[0025] Further advantageous features of the present invention will be evident from the following description and drawings.

[0026] Embodiments of the present invention will now be described, by way of example only, with reference to the much simplified accompanying drawings in which:

[0027]FIG. 1 shows a perspective view of flow inducement or stirring apparatus for controlling the flow of molten metal materials attached to a wall that may for example be a furnace wall;

[0028]FIG. 2 shows a vertical cross-section view of the flow inducement or stirring apparatus and chamber/furnace wall shown in FIG. 1 taken on line II-II as shown in FIG. 1;

[0029]FIG. 3 shows a vertical, part sectional view through a furnace, molten metal material and flow inducement/stirring apparatus as shown in FIGS. 1 and 2;

[0030]FIG. 4 shows a part sectional side view of a second embodiment of a furnace fitted with a second embodiment of flow inducement/stirring apparatus acting in one direction to cause circulation of molten metal material in a vertical plane;

[0031]FIG. 5 shows a view similar to FIG. 4 but with the flow inducement/stirring apparatus acting in the opposed direction to extract molten metal materials from the furnace;

[0032]FIGS. 6 and 7 show plan and side views of typical circulatory flow patterns set up by the flow inducement/stirring apparatus as depicted in FIG. 4;

[0033]FIG. 8 shows a sectional side view of a third embodiment of a furnace in accordance with the present invention;

[0034]FIG. 9 shows schematically the flow of molten metal in the furnace of FIG. 8;

[0035]FIG. 10 shows a sectional plan view of a further embodiment of a furnace according to the present invention;

[0036]FIG. 11 shows a sectional side view of a furnace shown in FIG. 2 taken on line A-A, and

[0037]FIG. 12 shows a sectional side view of a furnace taken on line B-B of FIG. 10.

[0038] Referring to FIGS. 1-3 of the accompanying drawings, flow inducement or stirring apparatus 500 includes electromagnetic induction apparatus in the form of a generally rectangular box 501 connected to an inclined end wall 502 of a cradle or port 503 of the apparatus 500, being generally of right-angled isosceles triangle cross-section. The inclined wall 502 is angled at 45° to the vertical wall 504 and horizontal wall 505 of the cradle or support 503.

[0039] The manner in which the cradle or port 503 can be connected into the vertical end wall 600 of the furnace 601 should be evident from FIG. 3 of the drawings. The port or cradle 503 can be fixed into the wall 600 of the furnace 601 by creating an aperture 602 of an appropriate size and by utilising usual refractory techniques to fix the port in the aperture.

[0040] The electromagnetic induction apparatus 501 is connected to said end wall 502 by any appropriate means and acts through a thin metal carbide plate construction 506 (see FIG. 2) the metal plate construction 506 is made up of separate tiles.

[0041] The port or cradle 503 has an upper rectangular aperture 507 which in use leads straight into the upper surface of molten metal material M at the bottom of furnace 601 and which extends into the port or cradle 503, close to the electromagnetic induction apparatus 501 but on an opposite side of the thin plate 506 as will be evident from FIG. 3.

[0042] In use, as shown more particularly in FIG. 3 of the drawings, the electromagnetic induction apparatus 501 (which is in effect a linear motor) can be operated to induce a circulatory flow pattern in the molten metal. This circulatory motion depicted by the arrows in FIG. 3 is set up by the downwardly inclined magnetic driving force (represented by arrow A in FIG. 3) created by the flow inducement/stirring apparatus 501. The magnetic driving force (arrow A) is a powerful force directed essential axially of the electromagnetic induction apparatus 501 and thus at an angle of generally 45° parallel with the end wall 502 of the cradle or port 503.

[0043] Whilst in the aforedescribed embodiment the end wall 502 is set an angle of 45° it is possible that an alternative angle (for example 30° or 60°) could be chosen to suit the particular application or use of the electromagnetic induction apparatus.

[0044] It is envisaged that the electromagnetic induction apparatus 501 will be a powerful motor of variable speed, for example, of up to 50 Hz. Thus, during operation the electromagnetic induction apparatus 501 will be able to stir the molten metal material M at very fast flow rates in the vertical plane. The flow circulation set up in the molten material M is advantageous for several reasons. Firstly, any metal materials (for example, scrap metal and/or additives) introduced into the furnace on top of the molten material M will become almost immediately or at least very rapidly dragged down and submerged into the material however light they may be. Since such materials are rapidly submerged into the molten material M disadvantageous oxidation of same will be substantially prevented unlike in known furnaces where light materials can remain floating on the molten material.

[0045] Secondly, the circulatory flow induced in the molten material M is far more rapid than that of known stirring techniques which take place in a horizontal plane. Such stirring techniques typically stir the molten material M at about 1 Hz. The induction apparatus 501 is able to stir the molten metal material at much higher speeds because it sets up a downward flow at one end of the molten metal material rather than having to act generally from below over the whole height of molten material requiring a very deep magnetic field to be created.

[0046] Additionally and advantageously, alloy additives such as silicon can be charged through the opening 507 through the port 503 into the molten metal material M and rapidly dissolved into solution. The port 503 can be used as a one point introduction of fluxes and good mixing throughout the molten material.

[0047] Additionally and advantageously, the aperture 507 in the port 503 can be used for taking samples of the molten material, thus avoiding the need to open the main door of the furnace to take samples.

[0048] Additionally, the flow inducement/stirring apparatus 500 can be used not only for circulating the molten metal material M in a vertical plane but also for degassing in the holding furnace 601. A gas lance (not shown) can be introduced into the molten metal flow through the opening 507 to give good dispersion in the molten metal M around the bottom of the furnace.

[0049] Since the electromagnetic field induced by the electromagnetic induction apparatus may be selectively variable, the circulation of the molten metal material or stirring in a vertical plane can be set up at a controlled rate to suit different materials and/or conditions. The molten metal material M may be stirred at a controlled rate of up to about 15 T/minute. Advantageously, the provision of high stirring rates gives increased melt rate and much reduced temperature and reduced alloy stratification. Low running metal levels can be accommodated.

[0050] Whilst, as described, the electromagnetic induction apparatus 501 has been arranged to provide or induce a generally downward flow of molten metal material (as indicated by arrow A) to thereby bring about circulation of molten metal material in a vertical plane, it is envisaged that the apparatus 501 will be bi-directional. Thus, if required the apparatus 501 could be arranged to move the molten metal material generally upwardly in a reverse direction to arrow A. Such facility may be used for example to extract molten metal material M from the furnace, in a manner to be described.

[0051]FIGS. 4 and 5 show a second embodiment of flow inducement or stirring apparatus 500′ which consists of the electromagnetic induction apparatus 501 located on an existing or purpose made inclined wall 700 of a furnace 701. In this instance therefore, there is no cradle or port 503 adapted to connect the electromagnetic induction apparatus 501 to the furnace wall at an inclined angle to induce downward and/or upward flow or circulation in a vertical plane.

[0052] As shown in FIG. 4, the electromagnetic induction means 501 can be set to move the molten metal material M in a downward direction to cause circulatory motion of the molten material M in a vertical plane during the melting process. When it is desired to extract the molten metal material from the furnace, the electromagnetic induction means 501 can be set to drive the molten metal material in a reverse direction upwardly as shown in FIG. 5 to be transferred out of the furnace along the extraction chute 702, in a manner which should be evident from FIGS. 4 and 5. It is possible that the electromagnetic induction apparatus 501 and the extraction chute 702 are constructed together as a unit constituting flow inducement or stirring apparatus, said unit being adapted for connection to an existing vertical side wall of a furnace.

[0053]FIGS. 6 and 7 show the typical flow patterns that may be set up in the molten material M by the electromagnetic induction apparatus 501 operating as shown in FIG. 4.

[0054] Of course, it is possible that a furnace is provided with more than one electromagnetic induction apparatus 501 for example, electromagnetic induction apparatus 501 and port 503 could be connected at one end of a furnace 601 more particularly as shown in FIG. 3, in order to stir the molten material in the furnace and a second electromagnetic induction apparatus 501 could be provided at an opposite end of the furnace to extract the molten metal material along the chute 702, more particularly as shown in FIG. 5. Moreover, where two such electromagnetic induction apparatus 501 are provided they could be arranged to operate in cooperation with one an another.

[0055] Where the electromagnetic induction apparatus 501 is utilised to extract molten metal material from the melt M through extraction chute 702, it will normally be operated on a much lower speed so that the material does not spurt or gush forth uncontrollably from chute 702, which could obviously be hazardous for an operator.

[0056] Thus, it should be obvious, that the electromagnetic induction apparatus 501 may be set up to induce movement or flow of molten metal material in a vertical plane by arranging same at an angle to vertical. Where the chamber wall or furnace wall is vertical the flow inducement or stirring apparatus may require a port or cradle for attachment. Otherwise, if the chamber or furnace already has a suitably inclined wall or a purpose made inclined wall is provided, the electromagnetic induction apparatus may be attached thereto without the port or cradle.

[0057] Thus, the electromagnetic induction apparatus 501 can be retrofitted to most surfaces and can be used on round topped furnaces as well as being used on side well furnaces for circulation and metal submergence. It can also be fitted to static or tilting furnaces.

[0058] Another benefit is the flexibility that the system of transfer or moving molten metal by use of the electromagnetic induction apparatus in accordance with the present invention provides. Since the electromagnetic induction apparatus is powerful enough to pump uphill, a static melter is no longer needed on a raised level compared to the holder/furnace or casting device.

[0059] Advantageously, the flow inducement or stirring apparatus allows metal to be transferred from the furnace without tilting or tap out blocks and it can be used during tilting/casting at controlled flow rates, to maintain consistent alloy composition, which is especially important where the densities of alloying elements are different to the molten metal material (e.g. aluminium).

[0060] Overall, the flow inducement or stirring apparatus 500 should allow increased production, lower energy consumption and melt loss, molten metal transfer, rapid submergence of light/medium weight scrap in the molten metal material, alloy and temperature homogeneity during casting, and faster solution of alloys.

[0061] Advantageously, no moving parts are required, which should yield low maintenance in addition to which the inducement or stirring apparatus is suitable for installation on static or tilting furnaces.

[0062] In particular, the flow inducement or stirring apparatus may be utilised in a side well furnace (see FIGS. 10-12). The furnace 100 includes a main chamber 112 and a side well chamber 113. Electromagnetic induction means 114 (see FIG. 12) is utilised to move molten material in the vicinity of the induction means 114 downwardly thereby creating a circulatory movement in a vertical plane. However, the downward driving movement of the molten material also drives the molten material in a generally horizontal circulatory fashion via passageway 172 and return passageway 170.

[0063] Thus, the powerful driving action of the flow inducement stirring apparatus 114 is able to rapidly circulate the molten metal material between the main chamber 112 and the side chamber 113 due to the initial downward pulling force exerted on the molten material adjacent thereto. Further discussion of the present invention in relation to a side well furnace is described later on in this specification.

[0064] With reference to FIG. 8, there is shown a single chamber furnace 10 generally of known form including a chamber 12 and a known heat source in the form of burner 16.

[0065] The chamber 12 has a floor 18 which includes a front inclined portion 20, a horizontal portion 22 and a rear inclined portion 24. The front inclined portion 20 and the horizontal portion 22 define a front region 26, and the rear inclined portion 24 defines a rear region 28 of the chamber 12. Electromagnetic induction means 14 is positioned in accordance with this embodiment of the present invention on inclined wall portion 20.

[0066] The chamber 12 is enclosed, i.e. surrounded by walls 30, with a liftable door 32 located in one of the walls 30. The liftable door 32 allows metal to be introduced into the chamber 12.

[0067] The furnace includes extraction means 34 for removing impurities from the chamber. As aforementioned, the furnace itself is generally of a type known per se and thus will not be described in further detail.

[0068] Supplying a current to the electromagnetic induction means 14 creates a molten metal flow.

[0069] Advantageously, since the electromagnetic induction means is inclined relative to the level position of the molten metal M, the molten metal flow has both horizontal and vertical components. This is best seen in FIG. 9 where arrows D schematically show the flow.

[0070] With reference to FIGS. 10 to 12, there is shown an alternative embodiment in the form of a two chamber furnace 100.

[0071] Furnace 100 is also generally of a known form and includes a main chamber 112, a sidewell chamber 113 and a heat source in the form of twin burners 116, the burners being located so as to direct heat into the main chamber 112.

[0072] In accordance with this embodiment of present invention, the furnace 100 further includes electromagnetic induction means 114, positioned in an inclined manner as shown.

[0073] The electromagnetic induction means 114 is located in the sidewell chamber 113, and the burners are located in the main chamber 112. This differs from the embodiment of FIG. 8 where both the electromagnetic induction means and the burner are located in the same chamber.

[0074] The sidewell chamber 113 has a sidewell inner side wall 158, a sidewell outer side wall 160, end wall 142 which is common with the main chamber, and liftable sidewell chamber door 162.

[0075] The main chamber 112 and the sidewell chamber 113 are in fluid communication by means of a first passageway 170 and a second passageway 172 through respective inner side walls 144,158 thereof

[0076] It can be seen from FIGS. 10 and 11 that molten metal M substantially covers the main and sidewell chamber floors 118, 148 and is maintained in the liquid state by the burners 116. The molten metal in the chambers has a height F between the floors 118,148 and the surface of the molten metal.

[0077] The first passageway 170 connects the front region 156 of the main chamber to the front region 126 of the sidewell chamber, and that the second passageway 172 connects the rear region 128 of the sidewell chamber to the rear region 154 of the main chamber.

[0078] The sidewell chamber is shielded from the heat produced by burners 116 in the main chamber by inner side walls 144,158.

[0079] In other embodiments, the sidewell chamber may be arranged relative to the main chamber such that the inner side walls are not required to shield the side chamber from the main chamber, for example, the first 170 and second 172 passageways could be greater in length so as to increase the distance between the two chambers, thereby reducing the effect in the sidewell chamber of the heat produced by the burners in the main chamber.

[0080] It should be noted that the induced flow in the molten metal creates predictable surface patterns on the molten metal surface, and therefore the extraction means can be positioned accordingly in the sidewell chamber so as to facilitate the efficient removal of solid or gaseous impurities.

[0081] As in the embodiment of FIG. 8, supplying a current to the electromagnetic induction means results in induced flow in the molten metal M.

[0082] However, the molten metal flow differs from that of the embodiment of FIG. 8 due to the two chamber arrangement linked by passageways. The electromagnetic induction means induces flow in the molten metal which, with reference to FIG. 10, creates a molten metal flow indicated by arrows E.

[0083] The molten metal in the main chamber 112 will flow into the sidewell chamber 113 via the first passageway 170 under the influence of the electromagnetic induction means 114 positioned in the sidewell chamber 113. The effect of drawing molten metal from the main chamber to the sidewell chamber via the first passageway will result in the molten metal in the sidewell chamber being drawn back into the main chamber via the second passageway, thus creating a continuous flow of molten metal between the two chambers.

[0084] The molten metal produced by melting the light and heavy scrap in the sidewell chamber will be drawn towards the second passageway 172 due to the molten metal flow set up by the electromagnetic induction means, and will enter the main chamber 112.

[0085] It can be seen from FIG. 11 that the second passageway roof surface 177 is below the height H of the molten metal M, and any impurities which are on the surface of the molten metal will not be drawn into the main chamber, with only clean metal being able to pass through the second passageway.

[0086] It is important that the height H of the molten metal is controlled to prevent large quantities of impurities from entering the main chamber 112 from the sidewell chamber 113. The height can be controlled by introducing more metal into either chamber.

[0087] A combination of impurities removal and controlling the height H of the molten metal reduces the potential for impurities to flow into the main chamber.

[0088] It is to be understood that the scope of the present invention is not to be unduly limited by the particular choice of terminology and that a specific term may be replaced or supplemented by an equivalent or generic term. For example, the term ‘cradle’ or ‘port’ could be replaced ‘support’. Further it is to be understood that individual features, system, method or functions relating to the flow inducement or stirring apparatus, port or electromagnetic induction apparatus, or furnace might be individually patentably inventive. The singular may include the plural and vice versa. Additionally, any range mentioned herein for any parameter or variable shall be taken as a disclosure of any derivable sub-range within that range or of any particular value of the variable or parameter arranged within, or at an end of, the range or sub-range.

[0089] Therefore, still further according to the present invention there is provided a furnace including a chamber for receiving metal, a heat source for heating the metal so as to melt it, and electromagnetic induction means being arranged so as to produce flow in the molten metal having a vertical component.

[0090] Advantageously, by inclining the electromagnetic induction means, the resultant molten metal flow is not limited to flow in the horizontal direction, and leads to a greater dispersal of heat throughout the molten metal, and hence a more efficient melting process.

[0091] Preferably, the chamber includes a front region located adjacent the electromagnetic induction means, and light scrap metal is introduced into the front region.

[0092] Advantageously the introduction of light scrap in the vicinity of the electromagnetic means causes the light scrap metal to be pulled downwards and submerged under the influence of the molten metal flow created by the electromagnetic induction means. This creates more efficient heat dispersal which reduces melt and process times, and also reduces exposure of the scrap metal to an oxidising atmosphere and therefore minimises metal loss by oxidation

[0093] Preferably the single chamber includes a rear region with an inclined floor, and heavy scrap metal is introduced into the rear region.

[0094] Advantageously this means that heavy scrap metal can be partly submerged in the rear region, therefore allowing the molten metal flow to wash through the heavy scrap. The molten metal in contact with the heavy scrap increases the heavy scrap temperature, and any impurities trapped inside the heavy scrap, for example, water, will evaporate as the temperature of the heavy scrap increases. This reduces the possibility of exposing water trapped inside the heavy scrap to confined and direct contact with the molten metal, because the rapid vaporisation as water comes into contact with the molten metal is clearly hazardous.

[0095] According to a further aspect of the present invention there is provided a method of melting metal in a furnace including the steps of providing a furnace including a chamber for receiving metal, providing a heat source, providing electromagnetic induction means, introducing metal into the chamber, heating the metal using the heat source so as to produce molten metal, supplying a current to the electromagnetic induction means so as to create a flow in the molten metal having a vertical component A potential limitation of furnaces with single chambers is having both the heat source and the resultant impurities from the scrap metal present in the same chamber, with the presence of impurities reducing the efficiency of the melt process.

[0096] Another limitation of single chamber furnaces is introducing the scrap metal in the same chamber as the heat source, thereby leading to metal loss through oxidation.

[0097] This can be partly overcome by employing the solutions as already defined, however, if the heat source and metal introduction are in the same chamber, the melting process will have a limited efficiency level.

[0098] Thus, according to a further aspect of the present invention there is provided a furnace having first and second chambers for receiving metal, the first chamber including a heat source for heating the metal thereby producing molten metal, the second chamber not having a heat source, and electromagnetic induction means arranged so as to cause molten metal flow between the first and second chambers.

[0099] Advantageously having two chambers enables the heat source to be isolated from the area in which scrap metal is introduced.

[0100] Furthermore, impurities produced from the scrap metal can be more efficiently extracted since the heat source is in a separate chamber, and hence the atmosphere is cooler.

[0101] According to a further aspect of the present invention there is provided a method of melting metal in a furnace including the steps of providing a furnace having first and second chambers for receiving metal, providing a heat source, providing electromagnetic induction means, introducing metal into the first chamber, heating the metal with the heat source so as to produce molten metal in the first chamber, supplying a current to the electromagnetic induction means to create a flow in the molten metal between the first and second chambers.

[0102] According to another aspect of the present invention there is provided a method of melting metal in a furnace comprising the steps of:

[0103] providing a furnace including a chamber for receiving metal,

[0104] providing a heat source,

[0105] providing electromagnetic introduction means,

[0106] providing an area for loading of heavy scrap,

[0107] melting a quantity of metal in the chamber,

[0108] supplying power to the electromagnetic inductions means so as to induce flow in the molten metal,

[0109] directing the flow so that molten metal contacts but does not submerge the heavy scrap. 

1. Flow inducement or stirring apparatus adapted for inducing downward and/or upward flow of molten metal material and/or circulation of molten metal material in a vertical plane, for example in a furnace.
 2. Apparatus as claimed in claim 1 adapted, in use, to create a horizontal flow of molten metal material and/or circulation of molten metal in a horizontal plane.
 3. Apparatus as claimed in claim 1 or claim 2 comprising or including electromagnetic induction apparatus.
 4. Apparatus as claimed in claim 3 in which the electromagnetic induction apparatus is arranged, in use, at an angle inclined to the horizontal (preferably, in use, at an angle 45° or 30° to 60°+/−5°) in order to create an upward and/or downward driving force on the molten metal.
 5. Apparatus as claimed in any one of claims 3 to 4 in which the electromagnetic induction apparatus is positioned on an inclined wall of a chamber of furnace, in use, containing molten metal.
 6. Apparatus as claimed in any one of claims 1 to 5 in which the induction electromagnetic apparatus is positionable at angle on a vertical chamber/furnace wall by means of an attachment cradle or port of the flow inducement or stirring apparatus and in which, preferably, the cradle or port includes an aperture which, in use, leads to molten metal material (e.g. in a furnace) and allows e.g. alloy additives such as silicon to be introduced into the molten metal material and allows samples of the metal to be taken as well as degassing and/or in which the flow inducement or stirring apparatus is arranged to provide a circulating flow in the melt, said circulation being in a vertical plane to enable solid scrap materials/light additives introduced on top of the melt to be dragged downwardly and submerged under the influence of the molten metal flow created by the flow inducement or stirring apparatus and/or in which the power or speed of the flow inducement or stirring apparatus is selectively variable (preferably the speed of the flow inducement or stirring apparatus is pre-settable to various values up to 50 Hz (+/−10 Hz) to suit different tasks to be undertaken by the flow inducement/stirring apparatus.
 7. Apparatus as claimed in any one of the preceding claims in which the flow inducement/stirring apparatus is bi-directional and, preferably, in which the flow inducement/stirring apparatus is adapted for utilisation in one direction to create circulation in a vertical plane in order to submerge and mix light scrap materials/additives into the melt, said flow inducement/stirring means being adapted for utilisation in its other directional mode to reverse the flow circulation and thus extract molten materials from a chamber or furnace.
 8. Apparatus as claimed in claim 3 or any claim dependent therefrom in which the electromagnetic induction means, in use, acts through a thin (preferably metal carbide) plate and, preferably, in which the plate is composed of tiles.
 9. A furnace or chamber for treating molten metal materials in combination with at least one flow inducement or stirring apparatus as claimed in any one of the preceding claims.
 10. A furnace or chamber for treating molten metal materials and at least one flow inducement or stirring apparatus arranged, in use, to induce downward and/or upward flow of molten metal material and/ or circulation of molten metal material in a vertical plane and, preferably, the furnace or chamber is adapted, in use, to create a horizontal flow of molten metal material and/or circulation of molten metal in a horizontal plane and/or the flow inducement means has electromagnetic induction means arranged at an angle to the horizontal in order to act at an inclined angle ( preferably, in use, at an angle 45° or 30° to 60°+/−5°) to molten metal in use in the furnace/chamber and/or in which the electromagnetic induction apparatus is positioned on an inclined wall, of the chamber of furnace, in use, containing molten metal and possibly in which the induction electromagnetic apparatus is positioned at angle on a vertical chamber/furnace wall by means of an attachment cradle or port of the flow inducement or stirring apparatus, said cradle or port preferably, including an aperture which, in use, leads to molten metal material in the furnace or chamber, said furnace of chamber preferably, having the flow inducement or stirring apparatus arranged to provide a circulating flow in the melt, said circulation being in a vertical plane and, preferably, the power or speed of the flow inducement or stirring apparatus is selectively variable to suit different tasks to be undertaken by the flow inducement/stirring apparatus and in which the speed of the flow inducement or stirring apparatus may be pre- settable to various values up to 50 Hz (+/−10 Hz).
 11. A furnace or chamber as claimed in claim 9 or 10 in which the flow inducement/stirring apparatus is bi-directional and, preferably, in which the flow inducement/stirring apparatus is adapted for utilisation in one direction to create circulation in a vertical plane in order to submerge and mix light scrap materials/additives into the melt, said flow inducement/stirring means being adapted for utilisation in its other directional mode to reverse the flow circulation and thus extract molten materials from a chamber or furnace and/or in which the electromagnetic induction means, in use, acts through a thin (preferably metal carbide) plate and preferably, in which the plate is composed of tiles.
 12. A method of treating molten metal material or recycling scrap metal, said method comprising inducing an upward and/or downward flow of molten metal and/or circulation of molten metal in a vertical plane, preferably by electromagnetic induction apparatus and/or comprising inducing a horizontal flow of molten metal material and/or circulation of molten metal in a horizontal plane and/or possibly in which the horizontal flow and/or circulation in a horizontal plane takes place between two chambers and possibly in which the electromagnetic induction means is arranged at 45° or 30° to 60°+/−5° and/or possibly including introducing scrap metal and/or alloy additives into the molten metal through an aperture in a port or cradle of the flow inducement/stirring apparatus and/or possibly including sampling and/or degassing through an aperture in a port or cradle of the flow inducement or stirring means or through said aperture and/or possibly including operating the flow inducement or stirring apparatus at about 50 +/−10 Hz and/or including operating the electromagnetic induction means bi-directionally.
 13. Use of electromagnetic induction means for inducing downward/upward flow of molten metal material in a vertical plane, for example in a furnace.
 14. A furnace including a chamber for receiving metal, a heat source for heating the metal so as to melt it, and electromagnetic induction means being arranged so as to produce flow in the molten metal having a vertical component.
 15. A method of melting metal in a furnace including the steps of providing a furnace including a chamber for receiving metal, providing a heat source, providing electromagnetic induction means, introducing metal into the chamber, heating the metal using the heat source so as to produce molten metal, supplying a current to the electromagnetic induction means so as to create a flow in the molten metal having a vertical component
 16. A furnace having first and second chambers for receiving metal, the first chamber including a heat source for heating the metal thereby producing molten metal, the second chamber not having a heat source, and electromagnetic induction means arranged so as to cause molten metal flow between the first and second chambers.
 17. A method of melting metal in a furnace including the steps of providing a furnace having first and second chambers for receiving metal, providing a heat source, providing electromagnetic induction means, introducing metal into the first chamber, heating the metal with the heat source so as to produce molten metal in the first chamber, supplying a current to the electromagnetic induction means to create a flow in the molten metal between the first and second chambers.
 18. A method of melting metal in a furnace comprising the steps of: providing a furnace including a chamber for receiving metal, providing a heat source, providing electromagnetic introduction means, providing an area for loading of heavy scrap, melting a quantity of metal in the chamber, supplying power to the electromagnetic inductions means so as to induce flow in the molten metal, directing the flow so that molten metal contacts but does not submerge the heavy scrap.
 19. In a furnace or chamber containing molten metal in use, connecting electromagnetic induction means at an inclined angle to the horizontal to induce a flow of molten metal downwardly and/or upwardly and/or a circulation in a vertical plane.
 20. Electromagnetic induction means adapted or arranged to induce a fast flow in molten metal >1 Hz e.g. 50 HZ (+/−15 Hz). 